The present application claims priority under 35 U.S.C. §119 of Japanese Application No. 2010-283302 filed on Dec. 20, 2010, the disclosure of which is expressly incorporated by reference herein in its entirety.
1. Field of the Invention
The present invention relates to an angle detection apparatus and a method of estimating an amount of eccentricity of the same.
2. Description of Related Art
A rotary encoder is an angle detection apparatus that detects a rotation angle of a rotation mechanism. The rotary encoder basically includes a circular grating disk and a measurer, for example, the grating disk being etched with a scale pattern including scale marks of several hundreds to several hundred thousands in a radial direction in an external peripheral portion, the measurer being arrayed proximate to the scale pattern of the grating disk and counting passed scale marks as the grating disk rotates. Such a rotary encoder is provided such that the grating disk engages a rotating portion of an object to be measured. The number of scale marks passed by a detector in association with rotation of the object to be measured is counted to detect a rotation angle of the object to be measured.
A rotation axis of the grating disk is, for example, a rolling bearing that rotatably supports the grating disk. The rotation accuracy of the rolling bearing is several ten μm. In general, the rotation axis is centered on the ideal rotation center of the detector and moves along the periphery at a maximum rotation accuracy of a radius. To fix the grating disk and the rotation axis, a jig or the like is used for highly accurate adjustment to match the center of the grating disk and the center of the rotation axis. Thus, the center of the grating disk moves on the same periphery as that of the rotation axis, causing eccentricity relative to the ideal rotation center. Such eccentricity causes an error in a detected angle, such as a change in apparent intervals between the scale marks due to misalignment of the radial position of the scale pattern that the detector reads for angle detection.
A conventional method of eliminating an eccentricity error of a grating disk is disclosed in Japanese Patent No. 4433240, for example. In the method, a grating disk is provided inside a scale pattern with numerous concentric patterns at the same intervals as pitches of the scale pattern. Two detectors are arrayed, which are a measurement detector reading the scale pattern and a correction detector provided at a position rotated by 90° from the measurement detector to read the concentric patterns. Then, the correction detector reads the concentric patterns to correct read signals of the scale pattern generated by the measurement detector, thus eliminating an impact of eccentricity from the read signals of the scale pattern.
The method, however, requires a special grating disk to which numerous concentric patterns are added for correction of eccentricity. Furthermore, with only one detector to read the concentric patterns, the amount of eccentricity of the grating disk eccentric on a two-dimensional plane surface cannot be accurately measured.
A feature of the present invention is to provide an angle detection apparatus and a method of estimating an amount of eccentricity of the same capable of accurately measuring an amount of eccentricity of a grating disk eccentric on a two-dimensional plane surface without requiring a special grating disk.
An aspect of the present invention provides an angle detection apparatus including a grating disk supported by a rotation axis; three or more detectors arrayed proximate to a front surface of the grating disk at equal distances in a circumferential direction of the grating disk; and an eccentricity amount estimator causing each of the detectors to detect a rotation angle of the grating disk rotated by a reference angle from a predetermined initial position; measuring an angle error at each of the detectors from a difference between the rotation angle and the reference angle; acquiring a tangential vector by rotating by 90° a directional vector of each of the detectors relative to the rotation center of the rotation axis; and calculating an eccentricity vector whose inner product with the tangential vector is the angle error.
Another aspect of the present invention provides a method of estimating an amount of eccentricity of an angle detection apparatus comprising a grating disk supported by a rotation axis and three or more detectors arrayed proximate to a front surface of the grating disk at equal distances in a circumferential direction of the grating disk. The method includes causing each of the detectors to detect a rotation angle of the grating disk rotated by a reference angle from a predetermined initial position; measuring an angle error at each of the detectors from a difference between the rotation angle and the reference angle; acquiring a tangential vector by rotating by 90° a directional vector of each of the detectors relative to the rotation center of the rotation axis; and calculating an eccentricity vector whose inner product with the tangential vector is the angle error.
The present invention is provided on the basis of a finding that the eccentricity of the rotation center functions as an eccentricity vector relative to the rotation angle detected by each of the detectors, thus causing the angle error, which is equivalent to the inner product of the eccentricity vector and the tangential vector at each of the detectors. In the present invention, the eccentricity vector can thus be calculated that represents the eccentricity of the rotation center relative to the detector center based on measureable values of the angle error generated at each of the detectors associated with rotation of the grating disk only by the reference angle and the directional vector of each of the detectors. Accordingly, the eccentricity of the rotation center can be corrected based on the calculated eccentricity vector, thus enhancing accuracy of the angle detection apparatus.
It is preferred in the present invention that the eccentricity vector be calculated for a plurality of times with respect to different reference angles rotated from the initial position; the detector center be determined from a plurality of calculated eccentricity vectors; and the eccentricity vector of the rotation center of the rotation axis relative to the detector center be calculated from one of an initial eccentricity vector from the detector center to the initial position and the eccentricity vector.
In the present invention, the eccentricity vector is repeatedly calculated to detect and correct the eccentricity of the rotation center of the rotation axis relative to the detection center.
It is preferred in the present invention that the reference angle be an average value of detected angles of the respective detectors. The average value may be calculated from detected angles of all detectors and alternatively from a detected angle of any detector. Averaging the detected angles of the detectors at different positions in the present invention reduces an effect of eccentricity and provides an approximate value of the reference position.
In the present invention, the reference angle may be detected by another angle detection apparatus connected to the rotation axis. Although an additional configuration is required in such a case, a reference position can be correctly detected.
According to the angle detection apparatus and the method of estimating the amount of eccentricity of the same of the present invention, the amount of eccentricity of the grating disk eccentric on a two-dimensional plane surface can be measured correctly even without using a special grating disk.
The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:
The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description is taken with the drawings making apparent to those skilled in the art how the forms of the present invention may be embodied in practice.
An embodiment of the present invention is explained below with reference to the drawings. With reference to
A detector 14 is arrayed opposite to the scale pattern 11. The detector 14 outputs sinusoidal detection signals corresponding to scale marks that pass through the detector 14 along with rotation of the grating disk 12. The angle detection apparatus 10 of the present embodiment is provided with four detectors 14. Output from the detectors 14 is connected to a calculator 17 through four respective interpolators 15 and counters 16. The counters 16 each receive from outside a latch signal and an initialization signal 16A to read a current count and reset the counter to zero, respectively.
The calculator 17 processes the detection signals input from the detectors 14 through the interpolators 15 and the counters 16 and acquires a rotation angle position or change amount and angle velocity of the rotation axis 13 and the grating disk 12. The calculator 17 is composed of a computer system that executes processing based on designated programs. The calculator 17 is operated externally from an input apparatus (not shown in the drawing) and outputs signals or images to an output apparatus. The calculator 17, which acts as an eccentricity amount estimator of the present invention, has programs that execute eccentricity vector calculation (refer to
In the angle detection apparatus 10, the rotation axis 13 is supported by a main body of the angle detection apparatus 10 through a bearing mechanism (not shown in the drawing) at the rotation centers of the grating disk 12 and the rotation axis 13; the grating disk 12 is fixed to the rotation axis 13; and the scale pattern 11 is provided on a front surface of the grating disk 12. The detectors 14 are supported by the main body of the angle detection apparatus 10. With reference to
In reality, however, the rotation axis 13 is misaligned due to axis support, as shown in
In
The calculation above of the eccentricity vector e is based on the principle below. In Step S11, each of the counters for the respective detectors is reset to 0 with the grating disk 12 at the initial position (any position may be acceptable). It is presumed that the rotation axis 13 is eccentric even at the initial position. It is assumed, however, that the eccentricity vector is 0 at the initial position, which is then set as the reference position of the eccentricity vector.
In the present embodiment, after the grating disk 12 is rotated in Step S12, an average of the measured angles θ1 to θ4 of all the detectors 14 is used as an actual measurement value of the reference position θN. Specifically, the reference angle θN can be provided in the expression (1) below where the total number of the detectors is n and the detected angle of the detector 14 having a detector number of i is θi.
Th reference position θN may be an average of two or more detected angles θi of the detectors 14 and alternatively may be a detected angle θi alone of any detector 14. It is effective, however, to use a larger number of detectors so as to enhance accuracy. In Step S14, the difference Δθi between the reference angle θN and the measured angle of the detector 14 having a detector number i (hereinafter referred to as detector i) due to eccentricity of the grating disk is provided in the expression (2) below.
[Expression 2]
Δθi=θN−θi (2)
If the scale pattern 11 of the grating disk 12 is provided with the scale marks at equal intervals, the angle error Δθi of the detector i is an error due to eccentricity of the grating disk 12. The angle error Δθi is an inner product of the eccentricity vector e and a vector rotated by 90° from the directional vector pi of the detector i. This point is explained below.
The detected angles of the respective detectors 14 have angle errors Δθ1, Δθ2, and Δθ3 due to eccentricity. With an angle φi defined by the eccentricity vector e and the tangential vector qi of the detector i, the angle error Δθi is a product of |e| cos φi and |qi|, where |e| cos φi is the size of the eccentricity vector e in the tangential vector qi and |qi| is the size of the tangential vector qi. The angle error Δθi is provided in the expression (3) below.
[Expression 3]
Δθi=|qi|×|e|cos φi (3)
Specifically, the angle error Δθi due to eccentricity is an inner product of the eccentricity vector e and the tangential vector qi of the detector i and is provided in the expression (4) below.
[Expression 4]
Δθi=qi·e (4)
The tangential vector qi of each of the detectors i is a vector orthogonal to the directional vector pi from the rotation center Oa to the detector i. The directional vector pi can be acquired from a mechanical configuration of the angle detection apparatus 10. Thus, rotating the directional vector pi by 90° in vector calculation converts the vector into the tangential vector qi. For such vector calculation of 90° rotation, a rotation matrix T can be used, such as shown in the expression (5) below, that rotates a vector by 90° counterclockwise in a two-dimensional space.
With such a rotation matrix T, the tangential vector qi is acquired from the directional vector pi as shown in the expression (6) below.
[Expression 6]
qi=T·pi (6)
Matrix notation of the eccentricity vector e, the directional vector pi, and the tangential vector qi is provided in the expressions (7) and (8) below.
A case of three detectors 14 is described above. A similar relationship is also established in a case of four or more detectors 14. A case of n pieces of detectors 14 is represented as the expression (9) below, and the expression (8) above is provided as the expression (10).
Solving the expression (10) for e is provided as the expression (11) below.
[Expression 11]
PtΔΘ=PtPe
∴e=(PtP)−1PtΔΘ (11)
Thus, the eccentricity vector e with the grating disk 12 rotated by an angle θ can be determined by using the angle error Δθ1 and the directional vector pi.
In the explanation above on the eccentricity vector calculation, it is assumed that the eccentricity vector e at the initial position is 0. In reality, however, the eccentricity vector e is not 0. It is thus preferable to perform eccentricity correction described below (refer to
In
[Expression 12]
eest=e+einit (12)
Such an initial eccentricity vector einit can be determined as below. With reference to
The eccentricity vector calculation is repeated for a specified number of times with different reference angles θN (e.g., positions P1 to P3 in
The present invention is not limited to the above-described embodiment and is deemed to include variations and improvements within a range to achieve the advantages of the present invention. In the eccentricity correction, the eccentricity vector einit from the rotation center Oa to the initial position Pinit is effective until the initial position is changed. Thus, the initial eccentricity vector einit may be acquired only once at the beginning of operation of a day. In the embodiment above, the eccentricity vector is calculated at a plurality of positions to acquire the virtual circle Ls′ and the rotation center Oa. Alternatively, a position detector (origin detector) may be added separately to the rotation axis 13 or the grating disk 12 such that the initial eccentricity amount at the time of initialization is measured and stored appropriately so as to be retrieved from a memory as required.
In the embodiment above, the grating disk 12 is rotated only by the reference angle θN from the initial position. Alternatively, the reference angle θN may be acquired from measurement after appropriate angle rotation. In the present invention, the eccentricity vector e is estimated based on the angle error Δθi due to eccentricity which is the difference between the detection angle θi of each of the detectors 14 and the reference angle θN. It is thus desirable that the reference angle θN be provided such that the error due to eccentricity and the like is minimized. For example, the reference angle may be an average of detected angles θi of all the detectors 14 in the angle detection apparatus 10. Alternatively, the reference angle may be an angle calibrated/corrected in existing various methods of calibration/correction (including self calibration).
The present invention is suitable to an angle detection apparatus that detects an angle position or angle velocity in a rotating portion.
It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to exemplary embodiments, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular structures, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.
The present invention is not limited to the above-described embodiments, and various variations and modifications may be possible without departing from the scope of the present invention.
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Entry |
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English Translation of JP 2011099802 A. |
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